EasYgen 3000 Technical Manual

5/26/2018 EasYgen 3000 Technical Manual

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37223E

Installation

Software Version: 1.10xx

Part Numbers: 8440-1816 / 8440-1817 / 8440-1818 / 8440-1831

Manual 37223E

easYgen-3000 Series (Package P1)Genset Control


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Manual 37223E easYgen-3000 Series (Package P1) - Genset Control

Page 2/67 Woodward

WARNING

Read this entire manual and all other publications pertaining to the work to be performed before instal-

ling, operating, or servicing this equipment. Practice all plant and safety instructions and precautions.

Failure to follow instructions can cause personal injury and/or property damage.

The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtempe-

rature, or overpressure, where applicable) shutdown device(s), that operates totally independently of

the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or oth-

er type of prime mover with possible personal injury or loss of life should the mechanical-hydraulicgovernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the lin-

kage(s), or the controlled device(s) fail.

Any unauthorized modifications to or use of this equipment outside its specified mechanical, electric-

al, or other operating limits may cause personal injury and/or property damage, including damage to

the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" with-

in the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,

and (ii) invalidate product certifications or listings.

CAUTION

To prevent damage to a control system that uses an alternator or battery-charging device, make sure

the charging device is turned off before disconnecting the battery from the system.

Electronic controls contain static-sensitive parts. Observe the following precautions to prevent dam-

age to these parts.

Discharge body static before handling the control (with power to the control turned off, contact a

grounded surface and maintain contact while handling the control).

Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.

Do not touch the components or conductors on a printed circuit board with your hands or with

conductive devices.

OUT-OF-DATE PUBLICATION

This publication may have been revised or updated since this copy was produced. To verify that you

have the latest revision, be sure to check the Woodward website:

http://www.woodward.com/pubs/current.pdf

The revision level is shown at the bottom of the front cover after the publication number. The latest

version of most publications is available at:

http://www.woodward.com/publications

If your publication is not there, please contact your customer service representative to get the latest

copy.

Important definitions

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.

NOTE

Provides other helpful information that does not fall under the warning or caution categories.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be

correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.

Woodward

All Rights Reserved.
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Manual 37223E easYgen-3000 Series (Package P1) - Genset Contr

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Revision History

Rev. Date Editor Changes

NEW 06-11-23 TP Release

A 07-06-29 TP Minor corrections

B 08-02-07 TP Sheet metal housing information added

C 08-07-24 TP Minor corrections

D 09-10-23 TE Minor corrections

E 10-03-12 TE Minor corrections

Content

Document Overview .................................................................................................................................

CHAPTER 1.GENERAL INFORMATION.......................................................................................

CHAPTER 2.ELECTROSTATIC DISCHARGE AWARENESS............................................................

Application ..............................................................................................................................................CHAPTER 3.MARINE USAGE.................................................................................................. 1

1

Plastic Housing .......................................................................................................................................CHAPTER 4.HOUSING........................................................................................................... 1

1Panel Cutout ................................................................................................................................ 1Dimensions .................................................................................................................................. 1Clamp Fastener Installation ......................................................................................................... 1Screw Kit Installation .................................................................................................................... 1

Sheet Metal Housing .............................................................................................................................. 1Dimensions .................................................................................................................................. 1Installation .................................................................................................................................... 1

Terminal Arrangement ........................................................................................................................... 1

CHAPTER 5.WIRING DIAGRAMS............................................................................................. 1

Power Supply .........................................................................................................................................

CHAPTER 6.CONNECTIONS.................................................................................................... 22

Charging Alternator ................................................................................................................................ 2Voltage Measuring (FlexRange)............................................................................................................. 2

Voltage Measuring: Generator ..................................................................................................... 2Voltage Measuring: Mains ............................................................................................................ 3Voltage Measuring: Busbar (System 1) 1Ph 2W ......................................................................... 3

Current Measuring .................................................................................................................................. 3Generator Current ........................................................................................................................ 3Mains Current 1-Phase ................................................................................................................ 4

Ground Current ............................................................................................................................ 4Power Measuring ................................................................................................................................... 4Power Factor Definition .......................................................................................................................... 4MPU (Pickup) ......................................................................................................................................... 4Discrete Inputs ....................................................................................................................................... 4

Discrete Inputs: Signal Polarity .................................................................................................... 4Discrete Inputs: Operation Logic .................................................................................................. 4

Relay Outputs (LogicsManager) ............................................................................................................. 5


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2Analog Inputs (FlexIn) .......................................................................................................................... 51Wiring Two-Pole Senders ............................................................................................................ 51Wiring Single-Pole Senders......................................................................................................... 52Wiring Single and Two-Pole Senders Simultaneously ................................................................ 53

Analog Outputs ...................................................................................................................................... 54Controller Wiring .......................................................................................................................... 54

Interfaces ............................................................................................................................................... 55RS-485 Serial Interfaces ............................................................................................................. 55RS-232 Serial Interface (Serial Interface #1, Interface #1) ......................................................... 56

CAN Bus Interfaces (FlexCAN) ................................................................................................... 56

CHAPTER 7.TECHNICAL DATA............................................................................................... 59CHAPTER 8.ENVIRONMENTAL DATA....................................................................................... 62CHAPTER 9.ACCURACY......................................................................................................... 63Suitable D-SUB Connector Housings ....................................................................................................

APPENDIX A.USEFUL INFORMATION....................................................................................... 6565

CAN Bus Pin Assignments of Third-Party Units .................................................................................... 65D-SUB DE9 Connector ................................................................................................................ 65RJ45/8P8C Connector ................................................................................................................. 66IDC / Header Connector .............................................................................................................. 66


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Figures and Tables

Figures

Figure 4-1: easYgen-3200 - plastic housing .............................................................................................................................

Figure 4-2: easYgen-3100 - sheet metal housing...................................................................................................................... Figure 4-3: Plastic housing - panel-board cutout ......................................................................................................................

Figure 4-4: Plastic housing easYgen-3000 - dimensions ..........................................................................................................

Figure 4-5: Plastic housing - drill plan......................................................................................................................................

Figure 4-6: Sheet metal housing easYgen-3000 - dimensions ..................................................................................................

Figure 4-7: Sheet metal housing - drill plan..............................................................................................................................

Figure 4-8: easYgen-3200 - terminal arrangement - rear view..................................................................................................

Figure 5-1: Wiring diagram overview....................................................................................................................................

Figure 6-1: Power supply.......................................................................................................................................................... 2

Figure 6-2: Power supply - crank waveform at maximum load................................................................................................. 2

Figure 6-3: Charging alternator input/output ............................................................................................................................ 2

Figure 6-4: Voltage measuring - generator............................................................................................................................... 2

Figure 6-5: Voltage measuring - generator windings, 3Ph 4W................................................................................................. 2

Figure 6-6: Voltage measuring - generator measuring inputs, 3Ph 4W .................................................................................... 2


Figure 6-8: Voltage measuring - generator measuring inputs, 3Ph 3W .................................................................................... 2


Figure 6-10: Voltage measuring - generator measuring inputs, 1Ph 3W .................................................................................. 2

Figure 6-11: Voltage measuring - generator windings, 1Ph 2W (phase-neutral) ...................................................................... 2

Figure 6-12: Voltage measuring - generator measuring inputs, 1Ph 2W (phase-neutral) ......................................................... 2

Figure 6-13: Voltage measuring - generator windings, 1Ph 2W (phase-phase) ........................................................................ 2

Figure 6-14: Voltage measuring - generator measuring inputs, 1Ph 2W (phase-phase) ........................................................... 2

Figure 6-15: Voltage measuring - mains ................................................................................................................................... 3

Figure 6-16: Voltage measuring - mains PT windings, 3Ph 4W............................................................................................... 3

Figure 6-17: Voltage measuring - mains measuring inputs, 3Ph 4W........................................................................................ 3





Figure 6-22: Voltage measuring - mains PT windings, 1Ph 2W (phase-neutral)...................................................................... 3Figure 6-23: Voltage measuring - mains measuring inputs, 1Ph 2W (phase-neutral)............................................................... 3

Figure 6-24: Voltage measuring - mains PT windings, 1Ph 2W (phase-phase) ........................................................................ 3

Figure 6-25: Voltage measuring - mains measuring inputs, 1Ph 2W (phase-phase)................................................................. 3

Figure 6-26: Voltage measuring - busbar (system 1) 1Ph 2W (phase-phase) ........................................................................... 3

Figure 6-27: Voltage measuring - busbar PT windings, 1Ph 2W (phase-neutral)..................................................................... 3

Figure 6-28: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-neutral).............................................................. 3

Figure 6-29: Voltage measuring - busbar PT windings, 1Ph 2W (phase-phase) ....................................................................... 3

Figure 6-30: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-phase)................................................................ 3

Figure 6-31: Current measuring - generator.............................................................................................................................. 3

Figure 6-32: Current measuring - generator, L1 L2 L3............................................................................................................. 4

Figure 6-33: Current measuring - generator, phase Lx ............................................................................................................. 4

Figure 6-34: Current measuring - mains current ....................................................................................................................... 4

Figure 6-35: Current measuring - mains, phase Lx................................................................................................................... 4

Figure 6-36: Current measuring - ground current ..................................................................................................................... 4

Figure 6-37: Power measuring - direction of power................................................................................................................. 4

Figure 6-38: MPU - principle overview.................................................................................................................................... 4

Figure 6-39: MPU input............................................................................................................................................................ 4

Figure 6-40: Minimal necessary input voltage depending on frequency................................................................................... 4

Figure 6-41: Discrete inputs - alarm/control input - positive signal.......................................................................................... 4

Figure 6-42: Discrete inputs - alarm/control input - negative signal......................................................................................... 4

Figure 6-43: Discrete inputs - alarm/control inputs - operation logic ....................................................................................... 4

Figure 6-44: Relay outputs........................................................................................................................................................ 5

Figure 6-45: Analog inputs - wiring two-pole senders.............................................................................................................. 5

Figure 6-46: Analog inputs - wiring single-pole senders .......................................................................................................... 5

Figure 6-47: Analog inputs - wiring single- and two-pole senders ........................................................................................... 5

Figure 6-48: Analog controller output - Wiring and external jumper setting............................................................................ 5


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Figure 6-49: RS-485 interface #1 - overview ............................................................................................................................ 55Figure 6-50: RS-485 Modbus - connection for half-duplex operation ...................................................................................... 55Figure 6-51: RS-485 Modbus - connection for full-duplex operation ...................................................................................... 55Figure 6-52: RS-232 interface - overview ................................................................................................................................. 56Figure 6-53: CAN bus #1 - overview ........................................................................................................................................ 56Figure 6-54: CAN bus #2 - overview ........................................................................................................................................ 56Figure 6-55: Interfaces - CAN bus - wiring of shielding .......................................................................................................... 57Figure 6-56: Interfaces - CAN bus - termination ...................................................................................................................... 57Figure 9-1: CAN bus pin assignment - D-SUB DE9 connector ................................................................................................ 65Figure 9-2: CAN bus pin assignment - RJ45/8P8C connector .................................................................................................. 66Figure 9-3: CAN bus pin assignment - IDC / Header ............................................................................................................... 66


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Tables

Table 1-1: Manual - overview....................................................................................................................................................

Table 4-1: Plastic housing - panel cutout ..................................................................................................................................

Table 6-1: Conversion chart - wire size .................................................................................................................................... 2

Table 6-2: Power supply - terminal assignment ........................................................................................................................ 2

Table 6-3: Charging alternator input/output - terminal assignment .......................................................................................... 2

Table 6-4: Voltage measuring - terminal assignment - generator voltage ................................................................................. 2

Table 6-5: Voltage measuring - terminal assignment - generator, 3Ph 4W............................................................................... 2

Table 6-6: Voltage measuring - terminal assignment - generator, 3Ph 3W............................................................................... 2Table 6-7: Voltage measuring - terminal assignment - generator, 1Ph 3W............................................................................... 2

Table 6-8: Voltage measuring - terminal assignment - generator, 1Ph 2W (phase-neutral)...................................................... 2

Table 6-9: Voltage measuring - terminal assignment - generator, 1Ph 2W (phase-phase)........................................................ 2

Table 6-10: Voltage measuring - terminal assignment - mains voltage..................................................................................... 3

Table 6-11: Voltage measuring - terminal assignment - mains, 3Ph 4W .................................................................................. 3



Table 6-14: Voltage measuring - terminal assignment - mains, 1Ph 2W (phase-neutral) ......................................................... 3

Table 6-15: Voltage measuring - terminal assignment - mains, 1Ph 2W (phase-phase) ........................................................... 3

Table 6-16: Voltage measuring - terminal assignment - busbar (system 1) 1Ph 2W (phase-phase).......................................... 3

Table 6-17: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-neutral) ........................................................ 3

Table 6-18: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-phase) .......................................................... 3

Table 6-19: Current measuring - terminal assignment - generator current ................................................................................ 3

Table 6-20: Current measuring - terminal assignment - generator, L1 L2 L3 ........................................................................... 4Table 6-21: Current measuring - terminal assignment - generator, phase Lx............................................................................ 4

Table 6-22: Current measuring - terminal assignment - mains current ..................................................................................... 4

Table 6-23: current measuring - terminal assignment - mains, phase Lx .................................................................................. 4

Table 6-24: Current measuring - terminal assignment - ground current ................................................................................... 4

Table 6-25: MPU - terminal assignment ................................................................................................................................... 4

Table 6-26: Discrete input - terminal assignment ..................................................................................................................... 4

Table 6-27: Relay outputs - terminal assignment...................................................................................................................... 5

Table 6-28: Analog inputs - terminal assignment - wiring two-pole senders ............................................................................ 5

Table 6-29: Analog inputs - terminal assignment - wiring single-pole senders ........................................................................ 5

Table 6-30: Analog inputs - terminal assignment - wiring single- and two-pole senders ......................................................... 5

Table 6-31: Bias signal outputs - analog or PWM .................................................................................................................... 5

Table 6-32: RS-485 interface #1 - pin assignment.................................................................................................................... 5

Table 6-33: RS-232 interface - pin assignment......................................................................................................................... 5

Table 6-34: CAN bus #1 - pin assignment ................................................................................................................................ 5

Table 6-35: CAN bus #2 - pin assignment ................................................................................................................................ 5

Table 6-36: Maximum CAN bus length.................................................................................................................................... 5

Table 9-1: CAN bus pin assignment - D-SUB DE9 connector................................................................................................. 6

Table 9-2: CAN bus pin assignment - RJ45/8P8C connector................................................................................................... 6

Table 9-3: CAN bus pin assignment - IDC / Header................................................................................................................. 6


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Chapter 1.

General Information

Document Overview

Type English German

easYgen-3000 Series

easYgen-3000 - Installation this manual 37223 GR37223

easYgen-3000 - Configuration 37224 GR37224

easYgen-3000 - Operation 37225 GR37225

easYgen-3000 - Application 37226 -

easYgen-3000 - Interfaces 37383 -

easYgen-3200 - Brief Operation Information 37399 GR37399easYgen-3100 - Brief Operation Information 37409 -

Table 1-1: Manual - overview

Intended UseThe unit must only be operated in the manner described by this manual. The prerequisite for a

proper and safe operation of the product is correct transportation, storage, and installation as well as careful oper-

ation and maintenance.

NOTE

This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,

configuration screens, and other details described, which do not exist on your unit, may be ignored.

The present manual has been prepared to enable the installation and commissioning of the unit. Dueto the large variety of parameter settings, it is not possible to cover every combination. The manual is

therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings may

be taken from the list of parameters in the configuration manual 37224 or from ToolKit and the respec-

tive *.SID file.


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Chapter 2.

Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others. To protect these components

from static damage, you must take special precautions to minimize or eliminate electrostatic discharges.

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static electricity on your body to groun

by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).

2. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials

Wear cotton or cotton-blend materials as much as possible because these do not store static electric

charges as easily as synthetics.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cigarette packages, cello

phane wrappers, vinyl books or folders, plastic bottles, etc.) away from the control, modules, and work

area as much as possible.

4. Opening the control cover may void the unit warranty.Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If yo

must remove the PCB from the control cabinet, follow these precautions:

Ensure that the device is completely voltage-free (all connectors have to be disconnected).

Do not touch any part of the PCB except the edges.

Do not touch the electrical conductors, connectors, or components with conductive devices or with ba

hands.

When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until youare ready to install it. Immediately after removing the old PCB from the control cabinet, place it in the

antistatic protective bag.

CAUTION

To prevent damage to electronic components caused by improper handling, read and observe the pre-

cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls,Printed Circuit Boards, and Modules.

NOTE

The unit is capable to withstand an electrostatic powder coating process with a voltage of up to 85 kVand a current of up to 40 A.


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Chapter 3.

Marine Usage

CAUTIONThe following notes are very important for marine usage of the easYgen genset control and have to be

followed.

NOTE

The specified marine approvals are only valid for metal housing units. They are only valid for plastic

housing units, if they are installed using the screw kit (refer toScrew Kit Installation on page15). In

this case, all

12 screws must be used and tightened accordingly.

Application

The easYgen-3000 has an internally isolated power supply.

If the easYgen is to be used on bridge and deck zones, an EMI filter (i.e. TIMONTA FSS2-65-4/3) must be used for

the power supply inputs.

Some additional, independent safety and protection devices are necessary to meet safety requirements of Rules

and Regulations of marineClassification Societies.

TheeasYgenis type approved by LR Lloyd's Register.

Please consider for final functional arrangements to comply with appropriate Lloyd's Register Rules as subject of

the Plan Approval process.


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Chapter 4.

Housing

The controls of the easYgen-3000 series are available with two different housings. Refer to the applicable sectiofor detailed information about installation and technical data of the respective housing type.

Plastic housing for front panel flush mounting with graphical LC display (easYgen-3200)

Figure 4-1: easYgen-3200 - plastic hous

Sheet metal housing for switch cabinet back mounting without display (easYgen-3100)

Figure 4-2: easYgen-3100 - sheet metal hous


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Plastic Housing

Panel Cutout

h' h H

b

B

b'

Figure 4-3: Plastic housing - panel-board cutout

Measure Description Tolerance

H Height Total 217 mm ---

h Panel cutout 183 mm + 1.0 mm

h' Housing dimension 181 mm

B Width Total 282 mm ---

b Panel cutout 249 mm + 1.1 mm

b' Housing dimension 247 mm

Depth Total 99 mm ---

Table 4-1: Plastic housing - panel cutout

The maximum permissible corner radius is 4 mm.

Refer toFigure 4-5 on page15 for a cutout drawing.


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Dimensions

282 mm

217 mm

99 mm

181 mm

87 mm

247 mm

Figure 4-4: Plastic housing easYgen-3000 - dimensio


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Clamp Fastener Installation

For installation into a door panel with the fastening clamps, proceed as follows:

1. Panel cutout

Cut out the panel according to the dimensions inTable 4-1.

Note:

Don't drill the holes if you want to use the clamp fasteners. If the holes are

drilled into the panel, the clamp fasteners cannot be used anymore!

cut-out

186,0

138,0

R3,5Rmax:

2. Remove terminals

Loosen the wire connection terminal screws on the back of the unit and

remove the wire connection terminal strip if required.

3. Insert screws in clamps

Insert the four clamping screws into the clamp inserts from the shown side(opposite of the nut insert) until they are almost flush. Do not completely

insert the screws into the clamp inserts.

4. Insert unit into cutout

Insert the unit into the panel cutout. Verify that the unit fits correctly in

the cutout. If the panel cutout is not big enough, enlarge it accordingly.

5. Attach clamp inserts

Re-install the clamp inserts by tilting the insert to a 45 angle. (1) Insert

the nose of the insert into the slot on the side of the housing. (2) Raise the

clamp insert so that it is parallel to the control panel.

1

2

6. Tighten clamping screws

Tighten the clamping screws (1) until the control unit is secured to the

control panel (2). Over tightening of these screws may result in the clamp

inserts or the housing breaking. Do not exceed the recommended tighten-

ing torque of 0.1 Nm.

1

2

7. Reattach terminals

Reattach the wire connection terminal strip (1) and secure them with theside screws.


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Screw Kit Installation

NOTE

Don't drill the holes if you want to use the clamp fasteners. If the holes are drilled into the panel, the

clamp fasteners cannot be used anymore!

NOTEThe housing is equipped with 12 nut inserts (refer toFigure 4-5 for their position), which must all be

tightened properly to achieve the required degree of protection.

Some versions of the plastic housing are not equipped with nut inserts and may not be fastened with

the screw kit.

In order to enhance the protection to IP 66, it is possible to fasten the unit with a screw kit instead of the clamp

fastener hardware.

Proceed as follows to install the unit using the screw kit:

1. Cut out the panel and drill the holes according to the dimensions inFigure 4-5 (dimensions shown in mm).

2. Insert the unit into the panel cutout. Verify that the unit fits correctly in the cutout. If the panel cutout is not

big enough, enlarge it accordingly.

3. Insert the screws and tighten to 0.6 Nm (5.3 pound inches) of torque. Tighten the screws with a crosswise

pattern to ensure even pressure distribution.

NOTE

If the thickness of the panel sheet exceeds 2.5 mm, be sure to use screws with a length of the panel

sheet thickness + 4 mm.

Cut-out dimension:249mm (+1,1mm) x 183mm (+1,0mm)

249.0

183.0

5.0254.0

24.5

124.5

224.5

21.5

91.5

161.5

194

259.0

5.7

4.512 x

Rmax: R 4.0

Figure 4-5: Plastic housing - drill p


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Sheet Metal Housing

Dimensions

84 mm

227 mm

250 mm

Figure 4-6: Sheet metal housing easYgen-3000 - dimensions


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Installation

The unit is to be mounted to the switch cabinet back using four screws with a maximum diameter of 6 mm. Drill

the holes according to the dimensions inFigure 4-7 (dimensions shown in mm).

42,4207,2

164,8 6,0 6,0

6,0 6,0

249,6

7,0

220,4213,4

7,042,4 42,4

Figure 4-7: Sheet metal housing - drill p


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Terminal Arrangement

6162636465666768697071727374757677787980

MP

U-

MPU+

24V+

24

V-

D+

DI12

DI11

DI10

DI09

DI08

DI07

DI06

DI05

DI04

DI03

DI02

DI01

6059585756555453525150494847464544434241

RS-232

21

RS-485

100V

201 2 3 4 5 6 7 8 9 10 11 12 1314 15 1617 18 19s2s1 +

+ -

22232425262728293031323334353637383940400V

100V

400V

100V

400V

100V

400V

100V

400V

100V

400V

100V

400V

100V

400V

100V

400V

100V

400V

L1 L2 L3 N L1 L2 L3 N L1 L2/NAO 02

+ -AO 01AI 03AI 02

+

AI 01

+

L1 L2 L3

s2s1 s2 s1 s2 s1L1

Pickup

Powersupply

Engineground

ProtectiveearthPE

Auxiliaryexcitation

DIComm

on

Discrete Inputs Relay Outputs

CANbus#2

RelayR09

RelayR10

RelayR11

RelayR12

RelayR08

RelayR07

RelayR06

RelayR05

RelayR01

RelayR02

RelayR03

RelayR04

Ground/MainsCT Generator CT Analog Inputs0 to 500 Ohm

0/4 to 20 mA

Analog Outputs+/-10 Vdc+/- 20 mA

PWM

PWMVOut

PWMVOut

Mains PT Generator PT Busbar PT

CANbus#1

Common

Common

Figure 4-8: easYgen-3200 - terminal arrangement - rear view

NOTE

The Protective Earth terminal 61 is not connected on the easYgen-3100 with sheet metal housing. Theprotective earth connection at the sheet metal housing must be used instead.


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Chapter 5.

Wiring Diagrams

[refer to next page for wiring diagram]

Figure 5-1: Wiring diagram overvi

NOTEThe Protective Earth terminal 61 is not connected on the easYgen-3100 with sheet metal housing. The

protective earth connection at the sheet metal housing must be used instead.


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Chapter 6.

Connections

WARNINGAll technical data and ratings indicated in this chapter are not definite! Only the values indicated in

Chapter 7: Technical Data on page59 are valid!

The following chart may be used to convert square millimeters [mm] to AWG and vice versa:

AWG mm AWG mm AWG mm AWG mm AWG mm AWG mm

30 0.05 21 0.38 14 2.5 4 25 3/0 95 600MCM 300

28 0.08 20 0.5 12 4 2 35 4/0 120 750MCM 400

26 0.14 18 0.75 10 6 1 50 300MCM 150 1000MCM 500

24 0.25 17 1.0 8 10 1/0 55 350MCM 185

22 0.34 16 1.5 6 16 2/0 70 500MCM 240

Table 6-1: Conversion chart - wire s


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Power Supply

WARNING Protective Earth

Protective Earth (PE) must be connected to the unit to avoid the risk of electric shock. The conductor

providing the connection must have a wire larger than or equal to 2.5 mm (14 AWG). The connectionmust be performed properly.

easYgen-3200:

This connection will be made using the screw-plug-terminal 61.

easYgen-3100:

The maximum permissible voltage differential between terminal 64 (B-) and terminal 61 (PE) is 15 V. On

engines where a direct connection between Battery minus and PE is not possible, it is recommended

to use an isolated external power supply if the voltage differential between Battery minus and PE ex-

ceeds 15 V.

The protective earth terminal 61 is not connected on the easYgen-3100 with sheet

metal housing. The protective earth connection at the sheet metal housing must be used instead.

Power suppl

y63

64 0 Vdc

12/24Vdc (8 to 40.0 Vdc)

8 to 40.0 Vdc

61 PE

Figure 6-1: Power supply

Terminal Description Amax

61 PE (protective earth) 2.5 mm

63 12/24Vdc (8 to 40.0 Vdc) 2.5 mm

64 0 Vdc 2.5 mm

Table 6-2: Power supply - terminal assignment

[ms]-50 0 50 100 150 200 250 300 350

[V]

9.010.0

11.0

12.0

Po

werSupply

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.0

Time

Initial voltage = 10.5 Vdc

0.0 Vdc for 10 ms

Continuous voltage = min. 8.0 Vdc

Continuous voltage range =

8.0 to 40.0 Vdc

Figure 6-2: Power supply - crank waveform at maximum load

NOTE

Woodward recommends to use one of the following slow-acting protective devices in the supply line

to terminal 63:

Fuse NEOZED D01 6A or equivalent

or

Miniature Circuit Breaker 6A / Type C (for example: ABB type: S271C6 or equivalent)


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Charging Alternator

Auxiliary excitation

63

65

8 to 40 Vdc

D+B+

D++

- G~

Figure 6-3: Charging alternator input/out


63 Battery B+ 2.5 mm

65 Auxiliary excitation output D+ 2.5 mm

Table 6-3: Charging alternator input/output - terminal assignm

NOTE

The charging alternator D+ acts as an output for pre-exciting the charging alternator during enginestart-up only. During regular operation, it acts as an input for monitoring the charging voltage.


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Voltage Measuring (FlexRange)

NOTE

DO NOT use both sets of voltage measuring inputs. The control unit will not measure voltage correctly

if the 100 V and 400 V inputs are utilized simultaneously.

NOTE

Woodward recommends protecting the voltage measuring inputs with slow-acting fuses rated for 2 to

6 A.

Voltage Measuring: Generator

L1L2

L3

N

Generatorvoltage

(phase

voltage)

GCB

32

N / Vcom

31

30

29L1 / Va

L2 / Vb

L3 / Vc

35

3433

36

100 Vac

400 Vac

100 Vac

400 Vac

G

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vacoptional

Figure 6-4: Voltage measuring - generator


29Generator voltage - phase L1 / Va

100 Vac 2.5 mm

30 400 Vac 2.5 mm

31Generator voltage - phase L2 / Vb

100 Vac 2.5 mm

32 400 Vac 2.5 mm

33Generator voltage - phase L3 / Vc

100 Vac 2.5 mm

34 400 Vac 2.5 mm

35Generator voltage - phase N / Vcom

100 Vac 2.5 mm

36 400 Vac 2.5 mm

Table 6-4: Voltage measuring - terminal assignment - generator voltage

NOTE

If parameter 1800 ("Gen. PT secondary rated volt.", refer to Configuration Manual 37224) is configured

with a value between 50 and 130 V, the 100 V input terminals must be used for proper measurement.

If parameter 1800 ("Gen. PT secondary rated volt.", refer to Configuration Manual 37224) is configured



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Voltage Measuring: Generator, Parameter Setting '3Ph 4W' (3-phase, 4-wire)

L1

L2

N

L3

N

A1

A2

A

B

B2

B1

C

C2

C1

N

A1

A2

A

B

C6

C5

B6

B5

A5

A6

B2

B1

C

C2

C1

L1

L2

N

L3

N

A1

A2

A

B

B6

B5

A5

A6

C

C6

C5

B2

B1

C2

C1

N

B1B2

C6

C5

A1

A2

B5B6

A

BC

C2

C1

A5

A6

Figure 6-5: Voltage measuring - generator windings, 3Ph 4

[1]

29 31 33 35

L1 L2 L3 N

Voltage 3Ph 4W

G

36343230

[4] [1] [4] [1] [4] [1] [4]

L1

L2

L3N

GCB

Figure 6-6: Voltage measuring - generator measuring inputs, 3Ph 4

3Ph 4W Wiring terminals NoteRated voltage (range) [1] 100 V (50 to 130 Veff.) [4] 400 V (131 to 480 Veff.) 1

Measuring range (max.) [1] 0 to 150 Vac [4] 0 to 600 Vac

easYgen terminal 29 31 33 35 30 32 34 36

Phase L1 L2 L3 N L1 L2 L3 N

Table 6-5: Voltage measuring - terminal assignment - generator, 3Ph 4

1 For different voltage systems, different wiring terminals have to be used. Incorrect measurements are possible if both voltage systems uthe same N terminal.


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L1

L2

L3

B2

C2

C1

A1

A2

B1

A

BC

L1

L2

L3

B1B2

C6

C5

A1

A2

B5B6

A

BC

C2

C1

A5

A6

Figure 6-7: Voltage measuring - generator windings, 3Ph 3W

Voltage 3Ph 3W

G

[1]

29 31 33 35

L1 L2 L3 N

36343230

[4] [1] [4] [1] [4] [1] [4]

L1

L2

L3

GCB

Figure 6-8: Voltage measuring - generator measuring inputs, 3Ph 3W

3Ph 3W Wiring terminals Note

Rated voltage (range) [1] 100 V (50 to 130 Veff.) [4] 400 V (131 to 480 Veff.)

2Measuring range (max.) [1] 0 to 150 Vac [4] 0 to 600 VaceasYgen terminal 29 31 33 35 30 32 34 36

Phase L1 L2 L3 --- L1 L2 L3 ---

Table 6-6: Voltage measuring - terminal assignment - generator, 3Ph 3W

2 For different voltage systems, different wiring terminals have to be used.


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L3

N

L1

N

B5

B6

C2

C1

A2A1

A

B1

B2

C6

C5

A6A5

C

N

C

A1

A2

A

B6

B5

A5

A6

C6

C5

B2

B1

C2

C1

Figure 6-9: Voltage measuring - generator windings, 1Ph 3

Voltage 1Ph 3W

[1]

29 31 33 35

L1 L2 L3 N

36343230

[4] [1] [4] [1] [4] [1] [4]

GL1

N

L3

GCB

Figure 6-10: Voltage measuring - generator measuring inputs, 1Ph 3


Rated voltage (range) [1] 100 V (50 to 130 Veff.) [4] 400 V (131 to 480 Veff.) 3Measuring range (max.) [1] 0 to 150 Vac [4] 0 to 600 Vac


Phase L1 N L3 N L1 N L3 N

Table 6-7: Voltage measuring - terminal assignment - generator, 1Ph 3



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NOTE

The 1-phase, 2-wire measurement may be performed phase-neutral or phase-phase. Please note to

configure and wire the easYgen consistently. Refer to the Configuration Manual 37224 for more infor-

mation.

'1Ph 2W' Phase-Neutral Measuring

N

L1

N

A2A1

AA6A5

L1

NN

B5

B6

A1

A2

A

Figure 6-11: Voltage measuring - generator windings, 1Ph 2W (phase-neutral)

Voltage 1Ph 2W

[1]

29 31 33 35

L1 L2 L3 N

36343230

[4] [1] [4] [1] [4] [1] [4]

GL1

N

GCB

Figure 6-12: Voltage measuring - generator measuring inputs, 1Ph 2W (phase-neutral)




Phase L1 N N N L1 N N N

Table 6-8: Voltage measuring - terminal assignment - generator, 1Ph 2W (phase-neutral)

4 For different voltage systems, different wiring terminals have to be used. Incorrect measurements are possible if both voltage systems usethe same N terminal.


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'1Ph 2W' Phase-Phase Measuring

L2

L1

B

A2A1A A6A5

B

B5

B6

A1

A2

A

Figure 6-13: Voltage measuring - generator windings, 1Ph 2W (phase-pha

Voltage 1Ph 2W

[1]

29 31 33 35

L1 L2 L3 N

36343230

[4] [1] [4] [1] [4] [1] [4]

GL1

L2

L3

GCB

Figure 6-14: Voltage measuring - generator measuring inputs, 1Ph 2W (phase-pha




Phase L1 L2 --- --- L1 L2 --- ---

Table 6-9: Voltage measuring - terminal assignment - generator, 1Ph 2W (phase-pha



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Voltage Measuring: Mains

L1

L2

L3N

Mainsvoltage

(phasevoltage)

MCB

N / Vcom

L1 / Va

L2 / Vb

L3 / Vc

21

22

23

24

25

26

2728

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vacoptional

Figure 6-15: Voltage measuring - mains


21Mains voltage - phase L1 / Va

100 Vac 2.5 mm

22 400 Vac 2.5 mm

23Mains voltage - phase L2 / Vb

100 Vac 2.5 mm

24 400 Vac 2.5 mm

25Mains voltage - phase L3 / Vc

100 Vac 2.5 mm

26 400 Vac 2.5 mm

27Mains voltage - phase N / Vcom

100 Vac 2.5 mm

28 400 Vac 2.5 mm

Table 6-10: Voltage measuring - terminal assignment - mains voltage

NOTE

If parameter 1803 ("Mains PT secondary rated volt.", refer to Configuration Manual 37224) is configured


If parameter 1803 ("Mains PT secondary rated volt.", refer to Configuration Manual 37224) is configured


NOTE

If the easYgen is intended to be operated in parallel with the mains, the mains voltage measuring in-

puts must be connected. If an external mains decoupling is performed, jumpers between busbar and

mains voltage measuring inputs may be installed.


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Voltage Measuring: Mains, Parameter Setting '3Ph 4W' (3-phase, 4-wire)

L1

L2

N

L3

N

A1

A2

A

B

B2

B1

C

C2

C1

N

A1

A2

A

B

C6

C5

B6

B5

A5

A6

B2

B1

C

C2

C1

L1

L2

N

L3

N

A1

A2

A

B

B6

B5

A5

A6

C

C6

C5

B2

B1

C2

C1

N

B1B2

C6

C5

A1

A2

B5B6

A

BC

C2

C1

A5

A6

Figure 6-16: Voltage measuring - mains PT windings, 3Ph 4

Mains voltage 3Ph 4W

MCB

L1

L2

L3N

[1]

21 23 25 27

L1 L2 L3 N

28262422

[4] [1] [4] [1] [4] [1] [4]

Figure 6-17: Voltage measuring - mains measuring inputs, 3Ph 4

3Ph 4W Wiring terminals NoteRated voltage (range) [1] 100 V (50 to 130 Veff.) [4] 400 V (131 to 480 Veff.) 6

Measuring range (max.) [1] 0 to 150 Vac [4] 0 to 600 Vac


Phase L1 L2 L3 N L1 L2 L3 N

Table 6-11: Voltage measuring - terminal assignment - mains, 3Ph 4



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L1

L2

L3

B2

C2

C1

A1

A2

B1

A

BC

L1

L2

L3

B1B2

C6

C5

A1

A2

B5B6

A

BC

C2

C1

A5

A6

Figure 6-18: Voltage measuring - mains PT windings, 3Ph 3W


MCB

L1

L2

L3

[1]

21 23 25 27

L1 L2 L3 N

28262422

[4] [1] [4] [1] [4] [1] [4]

Figure 6-19: Voltage measuring - mains measuring inputs, 3Ph 3W


Rated voltage (range) [1] 100 V (50 to 130 Veff.) [4] 400 V (131 to 480 Veff.)7Measuring range (max.) [1] 0 to 150 Vac [4] 0 to 600 Vac


Phase L1 L2 L3 --- L1 L2 L3 ---

Table 6-12: Voltage measuring - terminal assignment - mains, 3Ph 3W

7 For different voltage systems, different wiring terminals have to be used.


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L3

N

L1

N

B5

B6

C2

C1

A2A1

A

B1

B2

C6

C5

A6A5

C

N

C

A1

A2

A

B6

B5

A5

A6

C6

C5

B2

B1

C2

C1

Figure 6-20: Voltage measuring - mains PT windings, 1Ph 3


MCB

L1

L3

N

[1]

21 23 25 27

L1 L2 L3 N

28262422

[4] [1] [4] [1] [4] [1] [4]

Figure 6-21: Voltage measuring - mains measuring inputs, 1Ph 3




Phase L1 N L3 N L1 N L3 N

Table 6-13: Voltage measuring - terminal assignment - mains, 1Ph 3



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NOTE



mation.


N

L1

N

A2A1

AA6A5

L1

NN

B5

B6

A1

A2

A

Figure 6-22: Voltage measuring - mains PT windings, 1Ph 2W (phase-neutral)

L1

N


MCB

[1]

21 23 25 27

L1 L2 L3 N

28262422

[4] [1] [4] [1] [4] [1] [4]

Figure 6-23: Voltage measuring - mains measuring inputs, 1Ph 2W (phase-neutral)




Phase L1 N N N L1 N N N

Table 6-14: Voltage measuring - terminal assignment - mains, 1Ph 2W (phase-neutral)



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L2

L1

B

A2A1A A6A5

B

B5

B6

A1

A2

A

Figure 6-24: Voltage measuring - mains PT windings, 1Ph 2W (phase-pha


[1]

21 23 25 27

L1 L2 L3 N

28262422

[4] [1] [4] [1] [4] [1] [4]

MCB

L1

L2

L3

Figure 6-25: Voltage measuring - mains measuring inputs, 1Ph 2W (phase-pha




Phase L1 L2 --- --- L1 L2 --- ---

Table 6-15: Voltage measuring - terminal assignment - mains, 1Ph 2W (phase-pha



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Voltage Measuring: Busbar (System 1) 1Ph 2W

L1

L2

L3N

Busbar

voltage

(phase

voltage)

GCB

40

39

38

37L1

L2

MCB

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

100 Vac

400 Vac

Figure 6-26: Voltage measuring - busbar (system 1) 1Ph 2W (phase-phase)

Terminal Description Amax37

Busbar voltage (system 1) - phase L1100 Vac 2.5 mm

38 400 Vac 2.5 mm

39Busbar voltage (system 1) - phase L2 / N

100 Vac 2.5 mm

40 400 Vac 2.5 mm

Table 6-16: Voltage measuring - terminal assignment - busbar (system 1) 1Ph 2W (phase-phase)

NOTE

If parameter 1812 ("Busb1 PT secondary rated volt.", refer to Configuration Manual 37224) is confi-

gured with a value between 50 and 130 V, the 100 V input terminals must be used for proper measure-

ment.

If parameter 1812 ("Busb1 PT secondary rated volt.", refer to Configuration Manual 37224) is confi-

gured with a value between 131 and 480 V, the 400 V input terminals must be used for proper mea-

surement.


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Woodward Page 37/6

Voltage Measuring: Busbar (System 1), Parameter Setting '1Ph 2W' (1-phase, 2-wire)

NOTE



mation.


N

L1

N

A2A1

AA6A5

N

B5

B6

A1

A2

A

Figure 6-27: Voltage measuring - busbar PT windings, 1Ph 2W (phase-neutr

Busbar voltage 1Ph 2W

[1]

37 39

L1 N

4038

[4] [1] [4]

GCB

L1

N

L1

N

MCB

Figure 6-28: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-neutr



easYgen terminal 37 39 --- --- 38 40 --- ---

Phase L1 N --- --- L1 N --- ---

Table 6-17: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-neutr



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Page 38/67 Woodward


L2

L1

B

A2A1A A6A5

L1

L2B

B5

B6

A1

A2

A

Figure 6-29: Voltage measuring - busbar PT windings, 1Ph 2W (phase-phase)

Busbar voltage 1Ph 2W

[1]

37 39

L1 L2

4038

[4] [1] [4]

GCB

L1

L2

L3

L1

L2

L3

MCB

Figure 6-30: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-phase)



easYgen terminal 37 39 --- --- 38 40 --- ---

Phase L1 L2 --- --- L1 L2 --- ---

Table 6-18: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-phase)



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Woodward Page 39/6

Current Measuring

CAUTION

Before disconnecting the device, ensure that the current transformer/CT is short-circuited.

Generator Current

NOTE

Generally, one line of the current transformers secondary is to be grounded close to the CT.

Detail:Connection of the transducers

S2

s2L..

s1 (k)..L..

s2 (l)..

GS1

s1 6

5

4

3

s1 (k) - L1

s1 (k) - L2

L1

L2

L3N

GCB

s2 (l) - L2

Generatorcurrent

(phasecurrent)

../{x} A

../{x} A

../{x} A../{x}A-{x}=1or5

s1 (k) - L3

s2 (l) - L3

../{x} A

../{x} A

8

7

s2 (l) - L1../{x} A

G

Figure 6-31: Current measuring - genera


8 Generator current - phase L3 - transformer terminal s1 (k) 2.5 mm7 Generator current - phase L3 - transformer terminal s2 (l) 2.5 mm

6 Generator current - phase L2 - transformer terminal s1 (k) 2.5 mm

5 Generator current - phase L2 - transformer terminal s2 (l) 2.5 mm

4 Generator current - phase L1 - transformer terminal s1 (k) 2.5 mm

3 Generator current - phase L1 - transformer terminal s2 (l) 2.5 mm

Table 6-19: Current measuring - terminal assignment - generator curr


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Current Measuring: Generator, Parameter Setting 'L1 L2 L3'

L1

L2

N

L33~G

IGen L3IGen L2IGen L1

Figure 6-32: Current measuring - generator, L1 L2 L3

L1 L2 L3 Wiring terminals Notes

easYgen terminal 3 4 5 6 7 8

Phase s2 (k) L1 s1 (l) L1 s2 (k) L2 s1 (l) L2 s2 (k) L3 s1 (l) L3

Table 6-20: Current measuring - terminal assignment - generator, L1 L2 L3

Current Measuring: Generator, Parameter Setting 'Phase L1', 'Phase L2' & 'Phase L3'

L1

L2

N

L3 3~

G

IGen L1

L1

L2

N

L3 3~

G

IGen L2

L1

L2

N

L3 3~

G

IGen L3

Phase L1 Phase L2 Phase L3

Figure 6-33: Current measuring - generator, phase Lx

Wiring terminals Notes

Phase L1


Phase s2 (k) L1 s1 (l) L1 --- --- --- ---

Phase L2


Phase --- --- s2 (k) L2 s1 (l) L2 --- ---

Phase L3easYgen terminal 3 4 5 6 7 8

Phase --- --- --- --- s2 (k) L3 s1 (l) L3

Phase L1 and L3 13


Phase s2 (k) L1 s1 (l) L1 --- --- s2 (k) L3 s1 (l) L3

Table 6-21: Current measuring - terminal assignment - generator, phase Lx

13 This is valid if the generator voltage measurement is configured to 1Ph 3W (refer toVoltage Measuring: Generator, Parameter Setting '1Ph 3W' (1-phase, 3-wire) on page20).


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Mains Current 1-Phase

NOTE

Generally, one line of the current transformers secondary is to be grounded close to the PT.

Detail:Connection of the transducers

S2

s2L..

s1 (k)..L..

s2 (l)..

S1

s1

2

1

Mains

current

../{x} A

../{x} A{x} = 1 or 5

L1

L2

L3

N

MCB

../{x} A

s1 (k)

s2 (l)

Figure 6-34: Current measuring - mains curr


2 Mains current - transformer terminal s1 (k) 2.5 mm

1 Mains current - transformer terminal s2 (l) 2.5 mm

Table 6-22: Current measuring - terminal assignment - mains curr

Current Measuring: Mains, Parameter Setting 'Phase L1', 'Phase L2' & 'Phase L3'

L1

L2

N

L3

IMains L1

L1

L2

N

L3

IMains L2

L1

L2

N

L3

IMains L3

Phase L1 Phase L2 Phase L3

Figure 6-35: Current measuring - mains, phase

Wiring terminals Notes

Phase L1

easYgen terminal 1 2

Phase s2 (l) - L1 s1 (k) - L1

Phase L2


Phase s2 (l) - L2 s1 (k) - L2

Phase L3


Phase s2 (l) - L3 s1 (k) - L3

Table 6-23: current measuring - terminal assignment - mains, phase


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Ground Current

The mains current input can be configured to measure the mains current or ground current. Depending on how Pa-

rameter 'Input mains current as' is configured will determine if this input will measure the mains current (default)

or the ground current. Refer to configuration manual 37224 for more information.

NOTE

Generally, one line of the current transformers secondary is to be grounded.

2

1

L1

L2

L3

Ground current

G3~

L2

L3

L1G3~

L2

L3

L1

L2

L3

L1

Holmgreenconnection

Cable-type currenttransformer

G3~

L2

L3

L1

R R

R

One-pole transformer in star point

R

s1 (k)

s2 (l)

Figure 6-36: Current measuring - ground current


2 Ground current - transformer terminal s1 (k) 2.5 mm

1 Ground current - transformer terminal s2 (l) 2.5 mm

Table 6-24: Current measuring - terminal assignment - ground current


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Power Measuring

If the unit's current transformers are wired according to the diagram shown, the following values are displayed.

Parameter Description Sign displayed

Generator real power Genset generating kW + Positive

Generator real power Genset in reverse power - Negative

Generator power factor (cos ) Inductive / lagging + Positive

Generator power factor (cos ) Capacitive / leading - Negative

Mains real power Plant exporting kW + + Positive

Mains real power Plant importing kW - - Negative

Mains power factor (cos ) Inductive / lagging + Positive

Mains power factor (cos ) Capacitive / leading - Negative

S1 (K)

S2 (L)

S2 (L)

S1 (K)

Real powdisplay positi

Reacitive powdisplay inducti

Real powdisplay positi

Reacitive powdisplay inducti

GCBgenerator circuit breaker

MCBmains circuit breaker

easYgen

6

5

s1 (k)

G

s2 (l)

2

1

s1 (k)

s2 (l)

pos

pos

GENERATOR

indindQQ

PP

pos

pos

indQQ

PP

BUSBAR

MAINS

Figure 6-37: Power measuring - direction of pow

Power Factor Definition

The phasor diagram is used from the generator's view. Power factor is defined as follows.

Power Factor is defined as a ratio of the real power to apparent power. In a purely resistive circuit, the voltageand current waveforms are instep resulting in a ratio or power factor of 1.00 (often referred to as unity). In an in

ductive circuit the current lags behind the voltage waveform resulting in usable power (real power) and unusable

power (reactive power). This results in a positive ratio or lagging power factor (i.e. 0.85lagging). In a capacitive

circuit the current waveform leads the voltage waveform resulting in usable power (real power) and unusable

power (reactive power). This results in a negative ratio or a leading power factor (i.e. 0.85leading).

Inductive: Electrical load whose current waveform lags

the voltage waveform thus having a lagging power fac-

tor. Some inductive loads such as electric motors have a

large startup current requirement resulting in lagging

Capacitive: Electrical load whose current waveform

leads the voltage waveform thus having a leading pow

factor. Some capacitive loads such as capacitor banks

or buried cable result in leading power factors.


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power factors.

Different power factor displays at the unit:

i0.91 (inductive)

lg.91 (lagging)

c0.93 (capacitive)

ld.93 (leading)

Reactive power display at the unit:

70 kvar (positive) -60 kvar (negative)

Output at the interface:

+ (positive) - (negative)

In relation to the voltage, the current is

lagging leading

The generator is

over excited under excited

Control: If the control unit is equipped with a power factor controller while in parallel with the utility:

A voltage lower "-" signal is output as long as the

measured value is "more inductive" than the reference

set point

Example: measured = i0.91; set point = i0.95

A voltage raise "+" signal is output as long as the meas-

ured value is "more capacitive" than the reference set

point

Example: measured = c0.91; set point = c0.95

Phasor diagram:

inductive capacitive


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MPU (Pickup)

Sensor

toPickup

input

Rotating shaft

Figure 6-38: MPU - principle overview

< 1,0 V

24 V

MPU input (pickup)79

80

Shield

+

-

Figure 6-39: MPU input


79 MPU input - inductive/switching 2.5 mm

80 MPU input - GND 2.5 mm

Table 6-25: MPU - terminal assignment

NOTE

The shield of the MPU (Magnetic Pickup Unit) connection cable must be connected to a single point

ground terminal near the easYgen. The shield must not be connected at the MPU side of the cable.

NOTE

The number of teeth on the flywheel reference gear and the flywheel speed must be configured so that

the magnetic pickup input frequency does not exceed 14kHz.

0

2000

4000

6000

8000

10000

12000

0,1 1 10 100

[mVrms]

[kHz]

Figure 6-40: Minimal necessary input voltage depending on frequency


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Discrete Inputs

Discrete Inputs: Signal Polarity

The discrete inputs are electrically isolated which permits the polarity of the connections to be either positive ornegative.

NOTE

All discrete inputs must use the same polarity, either positive or negative signals, due to the common

ground.

Discrete Inputs: Positive Polarity Signal

67Discrete input 1

66

Power supply + (8 to 40 Vdc)

Power supply -

Discrete input 2

Discrete input 3

Discrete input 4

Discrete input 5

Discrete input 6

Discrete input 7

Discrete input 8

Discrete input 9

Discrete input 10

Discrete input 11

Discrete input 12

68

69

70

71

72

73

74

75

76

77

78












Figure 6-41: Discrete inputs - alarm/control input - positive sig


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Discrete Inputs: Negative Polarity Signal

Discrete input 166

Power supply -

Discrete input 2

Discrete input 3

Discrete input 4

Discrete input 5

Discrete input 6

Discrete input 7

Discrete input 8

Discrete input 9

Discrete input 10

Discrete input 11

Discrete input 12


67

68

69

70

71

72

73

74

75

76

77

78

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Power supply -

Figure 6-42: Discrete inputs - alarm/control input - negative signal


66 Discrete inputs - GND (common ground) 2.5 mm

67 Discrete input [DI 01]; pre-assigned to 'Emergency stop' 2.5 mm68 Discrete input [DI 02]; pre-assigned to 'Start in AUTO' 2.5 mm

69 Discrete input [DI 03]; pre-assigned to 'Low oil pressure' 2.5 mm

70 Discrete input [DI 04]; pre-assigned to 'Coolant temperature' 2.5 mm

71 Discrete input [DI 05]; pre-assigned to 'External alarm acknowledgement' 2.5 mm

72 Discrete input [DI 06]; pre-assigned to 'Enable MCB' 2.5 mm

73 Discrete input [DI 07]; fixed to 'Reply MCB' 2.5 mm

74 Discrete input [DI 08]; fixed to 'Reply GCB' 2.5 mm

75 Discrete input [DI 09] 2.5 mm




Table 6-26: Discrete input - terminal assignment

WARNINGDiscrete Input DI01 "Emergency Stop" is only a signaling input. This input may only be used to signal

that an external emergency stop button has been actuated. According to EN 60204, this input is not

approved to be used as the emergency stop function. The emergency stop function must be imple-

mented external to the control and cannot rely on the control to function properly.


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Discrete Inputs: Operation Logic

Discrete inputs may be configured to normally open (N.O.) or normally closed (N.C.) states. In the state N.O., n

potential is present during normal operation; if an alarm is issued or control operation is performed, the input is

energized. In the state N.C., a potential is continuously present during normal operation; if an alarm is issued or

control operation is performed, the input is de-energized.

The N.O. or N.C. contacts may be connected to the signal terminal as well as to the ground terminal of the dis-

crete input. See previous chapterDiscrete Inputs: Signal on page47 for details.

Discrete input (N.O.)Vdc (GND)

GND (Vdc)

Discrete input (N.C.)Vdc (GND)

GND (Vdc)

Figure 6-43: Discrete inputs - alarm/control inputs - operation lo


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Relay Outputs(LogicsManager)

A

BRelay output

external device

max. 250 Vac/dc

N /

2A

Figure 6-44: Relay outputs


Term. Com.

A B Form A, N.O. make contact Type

42 41 Relay output [R 01] {all}Ready for operation &

LogicsManagerN.O. 2.5 mm

43

46

Relay output [R 02] {all}Centralized alarm or

LogicsManagerSW 2.5 mm

44 Relay output [R 03] {all}Starter or

LogicsManager

SW 2.5 mm

45 Relay output [R 04] {all}Fuel solenoid / gas valve or


48 47 Relay output [R 05] {all}Preglow or


50 49 Relay output [R 06]

{0}LogicsManager SW

2.5 mm{1o}

{1oc}Command: close GCB N.O.

{2oc}


{0} LogicsManager SW

2.5 mm{1o}

Command: open GCB N.O.{1oc}{2oc}


{0}

LogicsManager SW2.5 mm

{1o}

{1oc}

{2oc} Command: close MCB N.O.


{0}

LogicsManager SW2.5 mm

{1o}

{1oc}

{2oc} Command: open MCB N.O.

57

60

Relay output [R 10] {all}Auxiliary services or


58 Relay output [R 11] {all}Alarm class A and B or


59 Relay output [R 12] {all}Alarm class C, D, E, F or


LogicsManager..using the functionLogicsManagerit is possible to freely program the relays

{all}-all appliction modes

{0}-no breaker mode; {1o}-GCB open; {1oc}-GCB open/close; {1oc}-GCB/MCB open/close

SW-switchable via the software; N.O.-normally open (make) contact

Table 6-27: Relay outputs - terminal assignment

CAUTION

The discrete output "Ready for operation OFF" must be wired in series with an emergency stop func-

tion. This means that it must be ensured that the generator circuit breaker is opened and the engine is

stopped if this discrete output is de-energeized. We recommend to signal this fault independently from

the unit if the availability of the plant is important.


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Analog Inputs (FlexIn)

It is recommended to use two-pole analog senders. This ensures an accuracy of 1% for 0 to 500 Ohm inputs an

1.2% for 0 to 20 mA inputs.

NOTE

The return wires (GND) should be connected to PE (terminal 61; for two-pole senders) or engine

ground (terminal 62; for single-pole senders) as close to the easYgen terminals as possible.

The following senders may be used for the analog inputs:

0/4 to 20 mA

resistive (0 to 500 Ohm)

VDO, 0 to 180 Ohm; 0 to 5 bar, Index "III"; 0 to 10 bar, Index "IV"

VDO, 0 to 380 Ohm; 40 to 120 , Index "92-027-004; 50 to 125 , Index "92-027-006

You may download a catalog of all available VDO sensors at the VDO homepage (http://www.vdo.com/siemens

Wiring Two-Pole Senders

NOTE

To ensure accurate system measurements, all VDO sending units must utilize insulated wires that are

connected to the easYgen analog input ground (terminals 9/11/13). Terminals 9/11/13 must have jum-

per wires connected to the PE connection (terminal 61). The Protective Earth terminal 61 is not con-

nected on the easYgen-3100 with sheet metal housing. The protective earth connection at the sheet

metal housing must be used instead.

Figure 6-45: Analog inputs - wiring two-pole send


9 Analog input [AI 01] ground, connected with PE 2.5 mm

10 Analog input [AI 01] 2.5 mm





Table 6-28: Analog inputs - terminal assignment - wiring two-pole send


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Wiring Single-Pole Senders

An accuracy of 2.5% may be achieved when using single-pole senders. The specified accuracy of 2.5% for

single-pole sensors can only be achieved if the differential voltage between the genset chassis ground and PE does

not exceed +/- 2.5V.

-

Wiring diagramfor single-pole sensors

12

14

13

Analog input

Analog input [AI 03]

Resistive / VDO

Resistive / VDO

[AI 03]

[AI 02]

0/4 to 20 mA

0/4 to 20 mA

Resistive / VDO

Documents

EasYgen 3000 Technical Manual